Flow analysis method

Abstract

Provided is a flow analysis method capable of predicting a flow state of a composite resin material by taking into account a change in filler dispersion degree of the composite resin material. In a flow analysis method for a composite resin material having a filler and a resin, in a certain process of identifying a region in which the composite resin material flows and analyzing a flow, an exothermic reaction speed of the composite resin material in the region is computed using a filler dispersion degree in the composite resin material, a temperature and the filler dispersion degree of the composite resin material in the region is computed using the computed exothermic reaction speed, and an exothermic reaction speed in a process subsequent to a process is computed using the computed filler dispersion degree.

The invention claimed is: 
     
       1. A flow analysis method for a composite resin material having a filler and a resin, the flow analysis method comprising:
 identifying a region in which the composite resin material flows; 
 dividing the region into a plurality of divided regions; 
 calculating a first exothermic reaction speed of the composite resin material in the region using an initial filler dispersion degree in the composite resin material in some of the plurality of divided regions; 
 calculating a temperature and a second filler dispersion degree of the composite resin material in the region using the first exothermic reaction speed in the some of the plurality of divided regions; 
 calculating a second exothermic reaction speed in a process subsequent to a certain process for flow analysis using the calculated second filler dispersion degree in the process for flow analysis in some of the plurality of divided regions; 
 determining if an elapsed time is less than a predetermined time, and when the elapsed time is less than the predetermined time
 recalculate and update the first exothermic reaction speed of the composite resin material in the region using the calculated second filler dispersion degree in the composite resin material in additional of the plurality of divided regions, 
 recalculate and update the temperature and the second filler dispersion degree of the composite resin material in the region using the updated first exothermic reaction speed in the additional of the plurality of divided regions, and 
 recalculate and update the second exothermic reaction speed in a process subsequent to a certain process for flow analysis using the updated second filler dispersion degree in the process for flow analysis in the additional of the plurality of divided regions; and 
 
 changing a velocity of a plunger based on the second exothermic reaction speed calculated. 
 
     
     
       2. The flow analysis method according to  claim 1 , wherein a filler dispersion degree computed in a certain divided region of the plurality of divided regions is used for computation of an exothermic reaction speed in an other divided region. 
     
     
       3. The flow analysis method according to  claim 1 , wherein the process continues until the exothermic reaction speed of the composite resin material is calculated using the filler dispersion degree in the composite resin material, and the temperature and the filler dispersion degree of the composite resin material in the region are calculated using the calculated first exothermic reaction speed. 
     
     
       4. The flow analysis method according to  claim 1 , wherein a flow velocity of the composite resin material in the region in the process is calculated using the calculated first exothermic reaction speed. 
     
     
       5. The flow analysis method according to  claim 1 ,
 wherein a viscosity of the composite resin material in the process is calculated using a viscosity equation having the temperature of the composite resin material as a variable, 
 the temperature and the filler dispersion degree of the composite resin material in the region is computed using the calculated viscosity of the composite resin material in addition to the first exothermic reaction speed, and 
 a viscosity of the composite resin material in a process subsequent to the process is computed by substituting the calculated temperature of the composite resin material into the viscosity equation. 
 
     
     
       6. The flow analysis method according to  claim 5 , wherein an equation having a reaction rate as a variable is used as the viscosity equation, the reaction rate being calculated by a calculation equation of an exothermic reaction speed having a filler dispersion degree as a variable. 
     
     
       7. The flow analysis method according to  claim 5 , wherein each of a flow velocity of the resin and a flow velocity of the filler is computed using the viscosity equation, and a filler dispersion degree of the composite resin material in the region in the process is computed using the calculated flow velocity of the resin and the calculated flow velocity of the filler. 
     
     
       8. The flow analysis method according to  claim 5 ,
 wherein a density of the composite resin material in the process is computed using a density equation having the filler dispersion degree in the composite resin material as a variable, 
 the filler dispersion degree in the region is calculated using the calculated density of the composite resin material in addition to the viscosity of the composite resin material, and 
 a density of the composite resin material in a process subsequent to the process is calculated by substituting the computed filler dispersion degree of the composite resin material into the density equation. 
 
     
     
       9. The flow analysis method according to  claim 5 ,
 wherein a thermal conductivity of the composite resin material in the process is computed using a thermal conductivity equation having the filler dispersion degree in the composite resin material as a variable, 
 the filler dispersion degree in the region is computed using the calculated thermal conductivity of the composite resin material in addition to the viscosity of the composite resin material, and 
 a thermal conductivity of the composite resin material in a process subsequent to the process is calculated by substituting the computed filler dispersion degree of the composite resin material into the thermal conductivity equation. 
 
     
     
       10. The flow analysis method according to  claim 5 ,
 wherein a specific heat of the composite resin material in the process is calculated using a specific heat equation having the filler dispersion degree in the composite resin material as a variable, 
 the filler dispersion degree in the region is calculated using the computed specific heat of the composite resin material in addition to the viscosity of the composite resin material, and 
 a specific heat of the composite resin material in a process subsequent to the process is computed by substituting the calculated filler dispersion degree of the composite resin material into the specific heat equation. 
 
     
     
       11. The flow analysis method according to  claim 5 ,
 wherein a density, a thermal conductivity, and a specific heat of the composite resin material in the process are calculated using a density equation having the filler dispersion degree in the composite resin material as a variable, a thermal conductivity equation having the filler dispersion degree in the composite resin material as a variable, and a specific heat equation having the filler dispersion degree in the composite resin material as a variable, 
 the temperature and the filler dispersion degree of the composite resin material in the region are calculated using the computed density, specific heat, and thermal conductivity of the composite resin material in addition to the viscosity of the composite resin material, and 
 a density, a specific heat, and a thermal conductivity of the composite resin material in a process subsequent to the process are calculated by substituting the computed filler dispersion degree of the composite resin material into each of the density equation, the specific heat equation, and the thermal conductivity equation. 
 
     
     
       12. A flow analysis system for performing flow analysis of a composite resin material having a filler and a resin, the flow analysis system comprising:
 a processor that
 identifies a region in which the composite resin material flows, 
 divides the region into a plurality of divided regions, 
 calculates a first exothermic reaction speed of the composite resin material using an initial filler dispersion degree in some of the plurality of divided regions, 
 calculates a temperature, a second filler dispersion degree, and a flow velocity of the composite resin material using the first exothermic reaction speed in the some of the plurality of divided regions, 
 calculates a second exothermic reaction speed in a process subsequent to a process for flow analysis using the calculated second filler dispersion degree and the temperature in the process for flow analysis in the some of the plurality of divided regions, 
 determines if an elapsed time is less than a predetermined time, and when the elapsed time is less than the predetermined time
 recalculates and updates the first exothermic reaction speed of the composite resin material in the region using the calculated second filler dispersion degree in the composite resin material in additional of the plurality of divided regions, 
 recalculates and updates the temperature and the second filler dispersion degree of the composite resin material in the region using the updated first exothermic reaction speed in the additional of the plurality of divided regions, and 
 recalculates and updates the second exothermic reaction speed in a process subsequent to a certain process for flow analysis using the updated second filler dispersion degree in the process for flow analysis in the additional of the plurality of divided regions, and 
 
 changes a velocity of a plunger based on the second exothermic reaction speed calculated; 
 
 a memory that stores data related to the temperature and the filler dispersion degree of the composite resin material calculated by the processor; and 
 a display device that displays data related to the flow velocity of the composite resin material calculated by the processor. 
 
     
     
       13. The flow analysis method according to  claim 1 , wherein
 the some of the plurality of divided regions is an amount of the plurality of divided regions that is less than the additional of the plurality of divided regions, and 
 the some of the plurality of divided regions contain different regions than the additional of the plurality of divided regions.